Methods and apparatus for loading cartons



June 25, 1957 H. v. HOLDING METHODS AND APPARATUS FOR LOADING CARTONS Filed Jan. 31. 195

2 Sheets-Sheet 1 @Ill mw 2 Sheets-Sheet 2 H. v. HOLDING METHODS AND APPARATUS FOR LOADING CARTONS June 25Y 1957 Filed Jan. s1, 195e Vrelation until the glue seam is rmly set.

United States yPatent E METHDS AND APPARATUS FOR LOADING CARTONS Hubert V. Bolding, lleersonville, Ind., assigner to Carton Associates Incorporated, Louisville, Ky., a corporation of Delaware Application January 31, 1956, Serial No. 562,524

Claims. (Cl. 53-35) This invention relates to methods and apparatus for loading cartons and more particularly to such methods and apparatus especially adapted for inserting cans into open-ended pre-glued cartons.

For present purposes the invention will be disclosed as applied to the loading of cylindrical cans into openended cartons of the type disclosed in United States Patent 2,559,948. Cartons of this type comprise an openended sleeve having cut-out portions adjacent the junctures of the four carton walls for receiving portions of the beads of the containers to lock the containers in the carton. Since such cartons dispense with end aps and thus use considerably less board than the so-called full cartons they are relatively inexpensive and have been adopted widely in the industry particularly for packing beer cans.

At present such cartons are loaded and glued in a continuous process in semi-automatic or fully automatic cartoning machines. The carton panels are wrapped around a groupof cans, usually siX, and the overlapping ends of the carton blank are glued together. In order to maintain the desired tight wrap, the entire carton and particularly the glue lap must be held in tightly assembled Generally this isaccomplished in the cartoning machines now in use by moving the carton between pressure applying belts over a distance as long as forty to fifty feet. Even-with this bulky, space-consuming apparatus, which increases the cost of packaging and reduces the rate of production, the glue seam often slips slightly with the result that the cans become loose in the carton and are susceptible of damage in shipment or handling and the locking formations in the carton are often rendered ineective to the extent that the cans may fall out of the carton.

It has been realized that substantially all ofthese disadvantages could be eliminated by loading the cans into pre-glued cartons. However since the combined width of the cans in side-by-side relation is necessarily greater than the width of the opening at the end of the carton to effect the desired locking action it has been generally regarded as not feasible to load the cans into a pre-glued carton without springing or tearing the loading end of the carton.

Prior to the present invention no satisfactory method or apparatus has-been devised forV loading the containers into a pre-glued cartonfwithout damaging the carton. It is the principal purposeand object of the present invention to provide such methods and apparatus for inserting cans and like containers into pre-glued open-ended cartons to thereby overcome the above-stated disadvantages of the prior methods.

It is a further object to provide improved methods and apparatus for loading containers into open-ended cartons to produce a tighter pack than heretofore possible, to permit more rapid loading, and to decrease the cost of the loading operation.

It is an additional object of the present invention to 2,796,709 Patented June 25, 1957 provide improved methods and apparatus for loading containers into open-ended cartons which may be performed or operated manually or withfully automatic machinery.

These and other objects are attained in the present invention by the provision of methods and apparatusfor grouping the cans opposite the open end of the erected pre-glued carton, olf-setting or staggering the cans so that the width of the can group is no greater than the Width of the interior of the carton, moving the can groups intothe carton, restraining the foremost can as it reaches the opposite end of the carton tand finally urging the trailingcan into the carton preferably with a snap action.

The invention and the additional objects and advantages thereof Will now be described in greater detail with reference to the accompanying drawings in which:

Figure 1 is a top plan view of one form of apparatus of the present invention showing the initial relationV of the can group and carton just prior to loading;

Figure 2 is a side elevation of the apparatus of Figure 1 with parts broken away to show details of construction;

Figures 3 and 4 are views similar to Figure l illustrating intermediate and nal stages, respectively, of the loading operation; and

Figure 5 is a fragmentary view of a portion of the cans showing their relation during the iinal loading stage.

As suggested above the present invention is particularly adapted i'orV loading a plurality of cans such as beer cans into an open-ended pre-glued sleeve carton of the type shown in United States Patent 2,559,948. In the drawings the cans are indicated generally at 20 and the carton into which-the cans-are to be loaded is indicated generally at 21. The carton 21 is preferably formed from a single blank folded along score lines to form a bottom wall 22 opposed side walls 24 and 26 and top wall panels 28 and 30; The latter are overlapped to provide a glue lap the edges of which are indicated atv 32. The overlap is such that the carton is of uniform width from top to bottom and is thus of substantially rectangular section.

Adjacent the juncture of the side walls with the top and bottom Walls cut-outs 34 are formed in the side walls through which the heads 36 of the cans 20 project when they are loaded into the carton as shown in Figure 4. The diameter of the cans is slightly greater than half the Width of the carton'interior so that when thecans are loaded in the carton they cause the side walls of the cartonV to bulge outwardly slightly. The diameter of the cans through the beads 36 is substantially greater than half the width of the interior of the carton so that the beads of the cans project through the upper and lower-cut-outs 34. Accordingly when the carton is properly dimensioned the cans are firmly locked in the carton.

Because of the dimensionalrelation betweenthe width of the cans and the interior of the carton the cans cannot be inserted into the carton in accordance with techniques known prior to the present invention without tearing or springing the carton. Inrecognition of this fact such cartons are assembled and glued after being loaded and are held in tightly assembled relation until the glue has firmly set. In practice it has been found diicult to maintainv the carton in the required position underk the proper pressure while it is moved away from the loading station particularly when the operation is conducted at speeds dictated by commercial requirements. Accordingly as suggested above the glue seam often slips resulting in a pack which is suiciently loose to permit the cans to fallout of the carton.

In accordance with the present invention a group of cans, usually six,rsuliicient to fill'the carton is positioned in a chute or guide assembly indicated generally at 3Q opposite theopen end of the carton 21 also Vsupported in the chute assembly. The chute assembly which is preferably fabricated from sheet metal comprises a at bottom wall YillV and opposedA side-walls 42. 'The side Vwalls are spaced apartV a distance-just suicient-to-l'oosely support the outer surfaceofthe carton side walls 2d and 26 and are of suiiicient height to assure that the carton will be supported in a manner to maintain itifully erected. A relatively rigid strap 44 extends across the end of the guide assembly 38 in which theV carton is positioned preferably at or slightly above the Yvertical center of the carton. The `chute assembly is open at its opposite end except for retainer straps f6 secured to the chute side walls 42 and having their free ends extending inwardly .thereof for a purpose to appear.

Rigidly secured to the inner surfaces of each of the opposed side walls 42 and extending longitudinally of the chute assembly is a pair of straps 48 the adjacent edges of which are spaced apart to form a slot l) which extends from the open end of the chute assembly to the inner open end of the carton. Slidably received in the opposed slots 50 are the opposite lateral edges of a plate 52 forming a part of a plunger assembly indicated generally at 54. Two vertically extending plunger heads 56 and 58 are `mounted on the plate 52, the former being rigidly secured by any suitable means to the forward edge of the plate 52 and the latter being rigidly secured to the outer end of a rod 60 slidably mounted in brackets V62 and 64 depending from the inner and outer edges of the plate 52. A coil spring is compressed between the bracket 64 and a pin 65 on the rod 60 to bias the plunger head S8 toward the carton. The distance between the pin 66 and the plunger head 58 is such that the latter is ofi-set with respect to the plunger head 56 longitudinally of the chute assembly a distance substantially equal to the radius of Vone of the cans 20. A handle 68 is secured by a pivot connection 70 to the outer edge of the plate 5t) to facilitate manual movement of the plunger assembly 54 toward and away from the carton 21. Suitable stops '72 may be provided to cooperate with the straps 46 to prevent complete withdrawal of the plunger assembly S4 from the chute assembly. The chute assembly is completed by a plate 74 which extends across the bottom of the chute assembly and is rigidly secured by any suitable means to the chute iloor dll. The thickness of the plate 74 is sulrcient to dispose the bottom of thecans which rest on the plate at or slightly above the level of the upper surface of the bottom carton wall 22. Since the thickness of the straps 4S secured to the opposed chute walls 42 is such that the inner surfaces are substantially ush with the inner surfaces of the carton side walls 24 and 26, the portion of the chute assembly in which the cans are ini- Y tially received in effect forms an extension of the interior of the carton.

The cans are loaded into the carton 2l by rst 'positioning the cans within the chute assembly between the plunger assembly 54 and the open end of the carton 21. When the cans are brought into contact with the respective plunger heads 56 and 5S they are disposed as shown in Figure l in two parallel rows of three each, the cans of one row being off-set with relation to the cans of the adjacent row a distance equal to substantially onehalf the diameter of one of the cans.

The cans are thus disposed in staggered relation to facilitate subsequent loading by what may be termed Vthe staggered method. When so arranged the total width of the can group through the beads 36 of the cans is substantially equal to the width of the interior of the carton 21. With the cans so grouped and the carton in place as shown in Figure l the plunger assembly 54 is advanced toward the open end of the carton. Almost at once the cans begin to rotate or roll in the direction shown by Ythe arrows in Figures l, 3 and 4, the Vrotation continuing until the loading operation is completed. It will be noted that since each of the cans in the leading row rotates counterclockwise as viewed in Figure l and each of the cans in the trailing row rotates in a clockwise direction as viewed in Figure l the adjacent peripheral portions of each of the cans moves in the same direction and at the same speed with an action similar to that of a gear train.

lf this rolling action is not established before the leading can reaches the open end of the carton it commences when the peripheral edge of the beads of the leading can contact the adjacent surfaces of the carton and permits the cans to roll smoothly into the carton with a minimum resistance and while imposing substantially no load on the carton side walls. The advancing movement of the plunger and cans is continued in a similar manner until the cans occupy the position shown in Figure 3 where the cans of the leading row occupy their final position longitudinally of the carton. The leading can and consequently all of the cans in the leading row are restrained against further movement by the strap 44. During continued movement of the plunger assembly 54 to the right as viewed in Figure 3, for example, the plunger head 58 remains stationary because of its resilient mounting and only the plunger head S6 continues to move. Continued movement of the trailing can row into the carton tends to increase the width of the can group and each can of the trailing row forces the can next adjacent in the leading row outwardly to project the bead of the latter through the cut-outs 34 in the carton. The cans in the leading row then occupy their final position in the carton. The cans of the trailing group are temporarily restrained against further movement into the carton since the width of the entire can group through the beads tends to be greater than the spacing between the carton side walls 24 and 26. However the advancing force imposed on the cans of the trailing row by the plunger head 56 causes the beads on the cans of one row to rise over the beads on the adjacent cans of the other row as shown in Figure 5. This action reduces the width of the can group suilciently so that the inherent resiliency of the carton permits the passage of the cans of the trailing row into nal position as shown in Figure 4. Thereafter normal handling of the carton will cause the slightly raised cans to move into their original position so that the carton will be of uniform height from side to side. It will be noted that when the cans are exerting maximum lateral pressure against the side walls of the carton the point of contact between the trailing can of the trailing row and the adjacent wall of the carton is la substantial distance inwardly of the end of the carton. Accordingly neither end of the carton is ever exposed to undue pressure and the possibility of tearing the carton at this point is entirely eliminated. Actual experience has shown that containers loaded into cartons in this manner are tightly wedged within the carton and display no tendency to rattle and are rmly locked within the carton so that they cannot :become dislodged accidentally. Sincethe gluing operation 1s not a part of the loading operation asin the prior processes the gluing can be accomplished undersubstantially ideal conditions in a carton factory, at speeds and under conditions ideally suited to provide a strong glue lap at minimum expense.

While for purposes of illustration the present invention has been disclosed as a simple manually operable 'loading device nevertheless it will be understood that by the use of available techniques known in the art, the car- Ytons and the cans may be automatically positioned as be considered in all respects as illustrative and not restric-V tive, the scope of the invention being indicated by the appended claims rather than by the foregoing description,

areas/o9 and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

What is claimed and desired to be secured by United States Letters Patent is:

l. The method of loading a group of containers into au open-ended prefastened sleeve carton comprising the steps of arranging containers of said group in oli-set relation in at least two rows so that the width of said' group is no greater than the width of the interior of the carton, moving the container group as a unit into one end of said carton until the foremost container of one row reaches its final position in the vopposite end of the carton, holding said foremost container in said position and urging the remaining containers into side-by-side relation with the containers of said one row.

2. The method of loading a group of containers into an open-ended pre-fastened sleeve carton comprising the steps of arranging the containers in parallel rows in which the containers of one row are relatively off-set longitudinally of the group with respect to containers of the adjacent row and with the outer edges of the containers substantially aligned with the opposite inner side surfaces of the carton, moving said group of containers as a unit into one end of said carton until the foremost container in one row reaches its final position in said carton, restraining said one row against further movement through said carton, and urging the remaining containers into side-by- A side relation with the containers of said one row.

3. Apparatus for loading a group of containers in an open ended pre-fastened sleeve carton comprising means for supporting an erected carton, a chute assembly for supporting and guiding said group of containers arranged in parallel rows for movement into said carton, and a plunger assembly mounted for movement axially of said chute toward and away from the adjacent end of said carton, said plunger assembly including separate pushers, each adapted to Contact one of said rows of containers, said pushers being normally relatively offset axially of said chute whereby when said plunger assembly is moved toward said carton said containers will be loaded into said carton in corresponding olset relation.

4. Apparatus for loading a group of containers into an open-ended pre-fastened sleeve carton comprising means for supporting an erected carton, a chute assembly for supporting and guiding said group of containers arranged in parallel rows for movement into said carton, a plunger assembly mounted for movement axially of said chute toward and away from the adjacent end of said carton, rst and second plunger heads adapted respectively to contact one of said rows of containers, said iirst plunger head being rigid with said plunger assembly, means mounting said second plunger head on said plunger assembly for reciprocating movement with respect thereto axially of said chute assembly, resilient means biasing said second plunger head away from said assembly to a limit position oii-set from said first plunger head a distance substantially equal to one-half the width of one of said containers, and stop means for preventing movement of said containers through said open-ended carton, whereby when said plunger assembly is moved toward said carton, said rows of containers will be loaded into said carton in oli-set relationship until the leading row contacts said stop means and in the continued movement of said plunger assembly the remaining containers of another row will be loaded into said carton in side-by-side relation with the containers in said leading row.

5. Apparatus for loading an even number of cylindrical containers into the open end of a pre-fastened carton comprising means for supporting an erected carton, ns for guiding said containers arranged in two parallel rows for movement into said carton, a plunger assembly mounted for reciprocating movement toward and away from the adjacent end of said carton, iirst and second plunger heads each adapted to contact one of said rows ot containers, meansmounting said first plunger head on said plunger assembly for reciprocating movement with respect thereto toward and away from the adjacent end of said carton, said second plunger head being rigid with said plunger assembly, means selectively maintaining said tirst plunger head olfset from said second plunger head toward said carton and for permitting said first plunger head to move to a position in side-by-side relation with said first plunger head, stop means for preventing movement of said containers through the remote end of said carton whereby when said plunger assembly is moved toward said carton, said rows of containers will be loaded into said carton in otiset relation until the leading row contacts said stop means whereupon said means for maintaining said rst plunger head offset with respect to said second plunger head is rendered ineiective and, in the continued movement of said plunger assembly, the containers of the second row will be loaded into said carton in side-by-side relation with the containers of said leading row.

6. Apparatus for loading a group of six cylindrical rimmed containers into an open ended, pre-fastened sleeve carton, the interior width of which is less than twice the diameter of one of said containers through the rim thereof, said carton having upper and lower openings for receiving the rims of said containers, comprising means for upporting an erected carton, means for guiding said group of containers arranged in two parallel rows of three each for movement into said carton,y a plunger assembly 'mounted for reciprocating movement toward and away from the adjacent end of said carton, first and second plunger heads each adapted to contact one of said rows of containers, means mounting said first plunger head on said plunger assembly for reciprocating movement with respect thereto toward and away from the adjacent end of said carton, said second plunger head being rigid with said plunger assembly, means for selectively maintaining said first plunger head offset from said second plunger head in a direction toward said carton at a distance substantiaily equal 'to one-half the diameter of one of said containers and for permitting said iirst plunger head to move to a position in side-by-side relation with said second plunger head, and stop means for preventing movement of said containers through the remote end of said carton whereby when said plunger assembly is moved toward said carton, said rows of containers will be loaded into said carton in offset relation until the leading row contacts said stop means whereupon said means for maintaining said iirst plunger head odset with respect to said second plunger head is rendered iuerlective and, in the continued movement of said plunger assembly, the containers of the second row will be loaded into said carton in side-by-side relation with the cans of said leading row, said containers being forced laterally outward in said carton to dispose their rims in said upper and lower carton openings.

7.A method of loading an even number of like cylindrical containers into an open ended, pre-fastened sleeve carton, the interior width of which is less than twice the maximum diameter of one of said containers, comprising the steps of supporting an erected carton in a substantially fixed position, arranging the containers in two parallel rows each containing the same number of cans, the containers of one row being relatively olset longitudinally of the group with respect to the containers of the adjacent row and with the outer edges of the containers substantially aligned with respect to the inner side surfaces of the carton, moving said containers as a group into one end of said carton, arresting the movement of the leading container in one row when said leading container reaches a position adjacent the opposite end of said carton, and urging the containers of the other row into side-by-side relation with the containers in said one row.

8. The method of loading a group of six like cylindrical containers into the open end of a pre-fastened erected carton, the interior width of Which is less than twice the'maximum diameter of'one of said containers, comprising the steps of supporting an. erected carton in a substantially lixed position, arranging the containers in parallel rows of three each, the containers of one row beingrelatively ofrset longitudinally of the group with respect to the containers of the adjacent row and with the outer edges of the containers substantially aligned with the respective inner side surfaces of the t carton, moving saidA group of Containers as a unit into said open end of said carton, arresting the movement of the leading container in one row when said leading container reaches a position adjacent the opposite end of said carton, and urging the remaining three containers into side-by-side relation with the respective three cans of said one row.

9. A method of loading a group of six like rimmed cylindrical containers into an erected open ended prefastened sleeve carton, the interior width of which is less than twice the diameter` of one or" said containers through the rim thereof, said carton having upper and lower openings for receiving the rims of said containers, comprising the steps of supporting an erected carton in a substantially fixed position, arranging the containers in parallel rows of three each, the containers of one row being relatively offset longitudinally of the group with respect to the containers of the adjacent row a distance substantially equal to one-half the diameter of one of tainers substantially aligned with respective inner side surfaces of the carton, moving said group of containers as a unit into one end of said carton, arresting theY movement of the containers in'one row when the leading container of said one rowV reaches a .ppositionradjacent the opposite end of said carton, and thereafter urging thevcontainers of the remaining row into side-by-side vrelation with the containers in said one row whereby the containers are forced laterally outward to dispose their rims in said upper and lower carton openings.

10. A method of loading an even number of like cylindrical containers into Yan openrended, pre-fastened sleeve carton, the interior width of which is less than twice the maximum diameter of one of said containers, comprising the steps of supporting an erected carton in a substantially iixed position, arranging the containers in two parallel rows each containing the same number of cans, the containers of one row being relatively oiset longitudinally of the group with respect to the containers of theradjacent row and with the outer edges of the containers substantially aligned with respect to the inner side surfaces of the carton, moving said containers as a group into one end of said carton, arresting the movement of said containers when the leading container in one row reaches a position adjacent the remote end of the carton, and thereafter moving said cans into sideyby-side relation in said carton.

said containers and with the outer edges of the con- Y No references cited 

